Controller arrangement for injection molding system

ABSTRACT

An injection molding apparatus (10) comprising a signal converter (1500) interconnected to a machine controller (MC) of an injection molding machine (IMM) that generates standardized signals (VPS), the signal converter (1500) receiving and converting the standardized signals (VS) to a command signal (MOPCS, PDCVS) that is compatible with a signal receptor or interface of an electrically powered actuator (940e, 941e, 942e) or a signal receptor, interface or driver of a proportional directional control valve (V, V1, V2) that drives a fluid driven actuator (940p, 941p, 942p) to respectively operate the electrically powered actuator (940e, 941e, 942e) or the proportional directional control valve (V, V1, V2) to move in a direction that operates to either begin an injection cycle and to end an injection cycle.

RELATED APPLICATIONS

This application is a continuation of and claims the benefit of priorityto PCT/US2017/034963 filed May 30, 2017 which claims the benefit ofpriority to U.S. Application Ser. No. 62/344,108 filed Jun. 1, 2016, thedisclosures of which are incorporated by reference as if fully set forthin their entirety herein.

The disclosures of all of the following are incorporated by reference intheir entirety as if fully set forth herein: U.S. Pat. No. 5,894,025,U.S. Pat. No. 6,062,840, U.S. Pat. No. 6,294,122, U.S. Pat. No.6,309,208, U.S. Pat. No. 6,287,107, U.S. Pat. No. 6,343,921, U.S. Pat.No. 6,343,922, U.S. Pat. No. 6,254,377, U.S. Pat. No. 6,261,075, U.S.Pat. No. 6,361,300, U.S. Pat. No. 6,419,870, U.S. Pat. No. 6,464,909,U.S. Pat. No. 6,599,116, U.S. Pat. No. 7,234,929, U.S. Pat. No.7,419,625, U.S. Pat. No. 7,569,169, U.S. patent application Ser. No.10/214,118, filed Aug. 8, 2002, U.S. Pat. No. 7,029,268, U.S. Pat. No.7,270,537, U.S. Pat. No. 7,597,828, U.S. patent application Ser. No.09/699,856 filed Oct. 30, 2000, U.S. patent application Ser. No.10/269,927 filed Oct. 11, 2002, U.S. application Ser. No. 09/503,832filed Feb. 15, 2000, U.S. application Ser. No. 09/656,846 filed Sep. 7,2000, U.S. application Ser. No. 10/006,504 filed Dec. 3, 2001, and U.S.application Ser. No. 10/101,278 filed Mar. 19, 2002 and PCT applicationno. PCT/US2011/029721 filed Mar. 24, 2011, PCT publication no.WO2012074879 (A1) and WO2012087491 (A1) and PCT/US2013/75064 andPCT/US2014/19210 and PCT/US2014/31000 and U.S. Publication No.20150239161 and U.S. Pat. No. 9,498,909.

BACKGROUND OF THE INVENTION

Injection molding systems that use an injection molding machine thatincludes a controller that controls the opening and closing positions ofa hydraulic or pneumatic valve pin have been used. The signaling of whenthe fluid driven valves are supposed to close or open is controlled by asignal generated by the injection molding machine (IMM) that is sent tothe solenoid of a fluid flow directional control valve (DCV) to instructthe DCV to move to a valve pin directional closed or valve pindirectional open position. The signal that is sent from the injectionmolding machine (or from an intermediate controller that is initiallysignaled by a screw position sensor SPSR that senses position of thebarrel screw BS of the injection molding machine) to the solenoidcomponent of the DCVs is typically a simple 0 volt signal for closed anda 24 volt signal for open (or sometimes a 0 volt signal for closed and120 volt signal for open). Such prior systems are standardized such thatall DCVs and IMMs are designed to be universally compatible forsimplicity of customer use and installation purposes.

SUMMARY OF THE INVENTION

In accordance with the invention there is provided a modular controlunit (1500) comprising:

a housing (1502) containing an electronic controller (16), multipleinput interfaces (1504, 1506), and at least one driver (MD, HVD, PVD),

a first input interface (1506) configured to receive a valve controlsignal (VS) specifying valve open or valve closed or start of injectioncycle and end of injection cycle, and outputting a data signal (1506 s)indicative thereof to the controller (16);

a second input interface (1504) configured to receive a pin positionsignal (PS) specifying a position of a valve pin along a continuous pathof travel and outputting a data signal (1504 s) indicative thereof tothe controller (16);

the controller (16) including a processor and computer readable mediawith instructions for pre-configured actuated control of valve pinposition, wherein the instructions, when executed by the processor,cause the processor to generate, based on the data signals (VS, PS) anoutput control signal (IS) for controlling valve pin position via atleast one of: a) a hydraulic proportional directional control valve (V,V1, V2), b) a pneumatic proportional directional control valve (P1, P2,P3), and c) an electric motor (940 e, 941 e, 942 e),

the at least one driver (MD, HVD, PVD) configured to receive the outputcontrol signal from the controller and generate a control unit outputsignal (MOPCS, PDCVS, PVS) that drives at least one of a) the hydraulicproportional directional control valve (V, V1, V2), b) the pneumaticproportional directional control valve (P1, P2, P3), and c) the electricmotor (940 e, 941 e, 942 e) for control movement of the valve pin.

The pin position signal (PS) is typically received from a sensor (950,951, 952) that senses a linear or rotational position of an actuator(940 e, 940 f) or a valve pin (1040, 1041).

The housing (1502) typically further contains a power management circuit(1508) that receives an input AC or DC power input, and wherein thepower management circuit outputs a power signal (1508 s) to the driver(MD, HVD, PVD).

The modular control unit is preferably adapted for use in an injectionmolding apparatus wherein an injection molding machine (IMM) or a fluidpressure unit (HPU) generates the input valve control signal (VS.)specifying valve open and valve closed or start of injection cycle andend of injection cycle, and a position sensor (950, 951, 952) generatesthe input pin position signal (PS).

The modular control unit can further comprise a user interface (1510)for receiving input from a human operator, the input being transmittedto the controller (16) and the input being stored on the computerreadable media.

The input is typically executed by the processor, along with theinstructions, for generating the output control signal.

The output control signal preferably specifies instructions for one ormore of: calibrating a valve pin position sensor, specifying a valve pinopen or closed position, specifying a valve pin position along thecontinuous path of travel, and specifying a valve pin velocity.

The instructions for pre-configured actuated control of valve pinposition can comprise sequential valve gating control parameters.

The instructions for pre-configured actuated control of valve pinposition can comprise simultaneous valve gating control parameters.

In another aspect of the invention there is provided a modular injectionmolding system control unit (1500) interconnected to an injectionmolding machine (IMM) controller (MC) comprising:

a housing (1502) containing an electronic controller (16), one or moreinput interfaces (1504, 1506), and at least one driver (MD, HVD, PVD),

at least one input interface (1506) configured to receive a valvecontrol signal (VS) specifying valve open and valve closed or start ofinjection cycle and end of injection cycle, and outputting a data signal(1506 s) indicative thereof to the controller (16);

the controller (16) including a processor and computer readable mediawith instructions for pre-configured actuated control of valve pinposition, wherein the instructions, when executed by the processor,cause the processor to generate, based on the data signal (1506 s) anoutput control signal (IS) for controlling valve open and valve closedposition or start of injection cycle and end of injection cycle via atleast one of: a) a hydraulic proportional directional control valve (V,V1, V2), b) a pneumatic proportional directional control valve (P1, P2,P3), and c) an electric motor (940 e, 941 e, 942 e),

the at least one driver (MD, HVD, PVD) configured to receive the outputcontrol signal (IS) from the controller (16) and generate a control unitoutput signal (MOPCS, PDCVS) that drives at least one of a) thehydraulic proportional directional control valve (V, V1, V2), b) thepneumatic proportional directional control valve (P1, P2, P3), and c)the electric motor (940 e, 941 e, 942 e) for control movement of thevalve pin.

The at least one input interface (1506) receives the valve controlsignal (VS) either directly from the injection molding machine (IMM)controller (MC) or indirectly from an intermediate control unit (HPU)that receives a corresponding instruction signal (SPS) from theinjection molding machine (IMM) that is at least indicative of valveopen and valve closed or start of injection cycle and end of injectioncycle.

In another aspect of the invention there is provided an injectionmolding apparatus (10) comprising an injection molding machine (IMM)having a drivably rotatable barrel screw (BS) that generates aninjection fluid (18), a heated manifold (40) that receives the injectionfluid (18) from the injection molding machine (IMM) and distributes theinjection fluid (18) to one or more gates (32, 34, 36), a mold (42)having a cavity (30) communicating with the gates to receive theinjection fluid (18),

the injection molding machine (IMM) including a machine controller (MC)or control unit (HPU) that generates one or more standardized signals(VS), wherein the standardized signals (VS) are compatible for receiptand use by a signal receptor, interface or driver of a standarddirectional control valve (12) to instruct the fluid directional controlvalve (12) to move to a position that routes a source of drive fluid toflow in a direction that drives an interconnected fluid drivableactuator (940 f, 941 f, 942 f) to move in a direction that operates tobegin an injection cycle and to end an injection cycle,

a signal converter (1500) interconnected to the machine controller (MC)or control unit (HPU), the signal converter (1500) being adapted toconvert the standardized signals (VPS) to a command signal (MOPCS,PDCVS) that is compatible with a signal receptor or interface of anelectrically powered actuator (940 e, 941 e, 942 e) or a signal receptoror interface of a proportional directional control valve (V, V1, V2)that is interconnected to a fluid driven actuator (940 p, 941 p, 942 p),

wherein the command signals (MOPCS, PDCVS) are converted by the signalconverter (1500) into a form, frequency, power or format that is usableby the signal receptor or interface of the electrically powered actuator(940 e, 941 e, 942 e) or the proportional directional control valve (V,V1, V2) to respectively cause the electrically powered actuator (940 e,941 e, 942 e) or the proportional directional control valve (V, V1, V2)to be driven in a direction that operates to either begin an injectioncycle or to end an injection cycle.

The direction that operates to begin an injection cycle is preferably adirection that operates to cause the actuator (940 e, 941 e, 942 e, 940p, 941 p, 942 p) or its associated valve pin (1040, 1041, 1042) to opena gate (32, 34, 36) and the direction that operates to end an injectioncycle is a direction that causes the actuator (940 e, 941 e, 942 e, 940p, 941 p, 942 p) or its associated valve pin (1040, 1041, 1042) to closethe gate (32, 34, 36).

The direction that operates to begin an injection cycle is an upstreamdirection in which the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942p) or its associated valve pin (1040, 1041, 1042) moves upstream from agate closed position to an open gate position (32, 34, 36) and thedirection that operates to end an injection cycle is a downstreamdirection in which the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942p) or its associated valve pin (1040, 1041, 1042) moves downstream froman open gate position to a closed gate position (32, 34, 36).

The standardized signals (VPS) typically comprise a voltage signal ofpredetermined voltage or magnitude indicative of a predeterminedrotational position of the barrel screw (BS) of the injection moldingmachine (IMM) that generates pressurized injection fluid (18) within theapparatus.

The apparatus (10) can further comprise one or more sensors (950, 951,952, SN, SC, SPSR, BPSR) that detect and generate one or more sensorsignals indicative of one or more of rotational or linear position of anactuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or its associatedvalve pin (1040, 1041, 1042), pressure or temperature of the injectionfluid 18 within a fluid channel (19) of the manifold (40) or within anozzle channel (42, 44, 46) or within the cavity (30) of the mold (33)or within a barrel of the injection molding machine (IMM), the apparatus(10) including an actuator controller (16) that receives and uses theone or more sensor signals in a program that:

instructs the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or itsassociated valve pin (1040, 1041, 1042) to travel during the course ofthe injection cycle to positions that correspond to a predeterminedprofile of injection fluid pressures, linear or rotational pinpositions, linear actuator or valve pin positions, barrel screwpositions, barrel pressures or actuator drive fluid pressures or that,

instructs the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or itsassociated valve pin (1040, 1041, 1042) such that the valve pin iswithdrawn from a closed gate position upstream at a reduced velocityover a selected path of upstream travel, or that,

instructs the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or itsassociated valve pin (1040, 1041, 1042) to travel such that the valvepin is driven downstream at a reduced velocity over a selected path oftravel where a distal tip end of the pin travel from upstream of thegate to a gate closed position, or that,

instructs the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or itsassociated valve pin (1040, 1041, 1042) to travel such that the valvepin is driven upstream or downstream to an intermediate position betweena gate closed position and a fully upstream position where the valve pinis maintained in the intermediate position for a selected period of timeduring the course of the injection cycle wherein, in the intermediateposition, the distal tip end of the valve pin restricts flow ofinjection of the injection to less than a maximum flow.

In another aspect of the invention there is provided a method ofbeginning and ending an injection cycle comprising operating anapparatus (10) in accordance with any of the foregoing describedapparatuses to perform an injection cycle.

In another aspect of the invention there is provided a signal converter(1500) for converting signals generated by an injection moldingapparatus (10) that is comprised of an injection molding machine (IMM)having a drivably rotatable barrel screw (BS) that generates aninjection fluid (18), a heated manifold (40) that receives an injectionfluid (18) from the injection molding machine (IMM) and distributes theinjection fluid (18) to one or more gates (32, 34, 36), a mold (42)having a cavity (30) communicating with the gates to receive theinjection fluid (18), wherein the injection molding machine (IMM)includes a machine controller (MC) or a control unit (HPU) thatgenerates one or more standardized signals (VS), wherein thestandardized signals (VS) are compatible for use by a signal receptor,interface or driver of a standard fluid directional control valve (12)to instruct the fluid directional control valve (12) to move to aposition that routes a source of drive fluid to flow in a direction thatdrives an interconnected fluid drivable actuator (940 f, 941 f, 942 f)to move in a direction that operates to begin an injection cycle and tomove in a direction that operates to end an injection cycle,

wherein the signal converter (1500) is interconnected to the machinecontroller (MC) or control unit (HPU), the signal converter (1500)receiving and converting the standardized signals (VPS) to a commandsignal (MOPCS, PDCVS) that is compatible with a signal receptor orinterface of an electrically powered actuator (940 e, 941 e, 942 e) or asignal receptor or interface of a proportional directional control valve(V, V1, V2) that drives a fluid driven actuator (940 p, 941 p, 942 p),

wherein the signal converter (1500) includes a processor that convertsthe command signals (MOPCS, PDCVS) into a form, frequency, power orformat that is usable by the signal receptor or interface of theelectrically powered actuator (940 e, 941 e, 942 e) or by the signalreceptor or interface of the proportional directional control valve (V,V1, V2) to respectively cause the electrically powered actuator (940 e,941 e, 942 e) or the proportional directional control valve (V, V1, V2)to be driven in a direction that operates to either begin an injectioncycle or to end an injection cycle.

The direction that operates to begin an injection cycle is preferably adirection that operates to moves the actuator (940 e, 941 e, 942 e, 940p, 941 p, 942 p) or its associated valve pin (1040, 1041, 1042) to opena gate (32, 34, 36) and the direction that operates to end an injectioncycle is a direction that operates to move the actuator (940 e, 941 e,942 e, 940 p, 941 p, 942 p) or its associated valve pin (1040, 1041,1042) to close the gate (32, 34, 36).

The direction that operates to begin an injection cycle is preferably anupstream direction in which the actuator (940 e, 941 e, 942 e, 940 p,941 p, 942 p) or its associated valve pin (1040, 1041, 1042) movesupstream from a gate closed position to an open gate position (32, 34,36) and the direction that operates to end an injection cycle is adownstream direction in which the actuator (940 e, 941 e, 942 e, 940 p,941 p, 942 p) or its associated valve pin (1040, 1041, 1042) movesdownstream from an open gate position to a closed gate position (32, 34,36).

The standardized signals (VS) typically comprise a voltage signal ofpredetermined voltage or magnitude indicative of a predeterminedrotational position of the barrel screw (BS) of the injection moldingmachine (IMM) that generates pressurized injection fluid (18) within theapparatus.

The signal converter (1500) typically further comprises one or moresensors (950, 951, 952, SN, SC, SPSR, BPSR) that detect and generate oneor more sensor signals indicative of one or more of rotational or linearposition of an actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) orits associated valve pin (1040, 1041, 1042), pressure or temperature ofthe injection fluid 18 within a fluid channel (19) of the manifold (40)or within a nozzle channel (42, 44, 46) or within the cavity (30) of themold (33) or within a barrel of the injection molding machine (IMM), theapparatus (10) including an actuator controller (16) that receives anduses the one or more sensor signals in a program that:

instructs the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or itsassociated valve pin (1040, 1041, 1042) to travel during the course ofthe injection cycle to positions that correspond to a predeterminedprofile of injection fluid pressures, linear or rotational pinpositions, linear actuator or valve pin positions, barrel screwpositions, barrel pressures or actuator drive fluid pressures or that,

instructs the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or itsassociated valve pin (1040, 1041, 1042) such that the valve pin iswithdrawn from a closed gate position upstream at a reduced velocityover a selected path of upstream travel, or that,

instructs the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or itsassociated valve pin (1040, 1041, 1042) to travel such that the valvepin is driven downstream at a reduced velocity over a selected path oftravel where a distal tip end of the pin travel from upstream of thegate to a gate closed position, or that,

instructs the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or itsassociated valve pin (1040, 1041, 1042) to travel such that the valvepin is driven upstream or downstream to an intermediate position betweena gate closed position and a fully upstream position where the valve pinis maintained in the intermediate position for a selected period of timeduring the course of the injection cycle wherein, in the intermediateposition, the distal tip end of the valve pin restricts flow ofinjection of the injection to less than a maximum flow.

In another aspect of the invention there is provided a method ofbeginning and ending an injection cycle comprising operating a signalconverter (1500) in accordance with any of the foregoing claims 7-11 toperform an injection cycle.

In another aspect of the invention there is provided an injectionmolding system comprised of an injection molding machine, a manifold, amold and a valve having an associated valve pin drivable by an actuatorbetween a gate closed position and a gate open position, the injectionmolding machine injecting a selected injection fluid to the manifoldwhich distributes the injection fluid to the valve, the injection fluidflowing through the gates into a cavity in the mold when the valve pinis in the gate open position,

wherein the system includes a first controller that includes a first setof instructions that generate a first set of one or more signals thatare adapted to instruct a drive mechanism for a first selected actuatorthat is adapted to be interconnected to the valve pin to drive the valvepin between gate closed and gate open positions,

the system comprising a second controller interconnected to the firstcontroller, the second controller receiving the first set of signalsfrom the first controller and including a second set of instructionsthat convert the received first set of signals to a second set ofsignals that are adapted to instruct a drive mechanism for a secondselected actuator that is interconnected to the valve pin to drive theinterconnected valve pin between gate closed and gate open positions.

The first selected actuator is typically a hydraulic or pneumaticactuator and the second selected actuator is preferably an electricallydriven actuator comprised of an electrically driven motor interconnectedto the valve pin. Typical electric actuator configurations andembodiments are shown and described in International ApplicationPublication No. WO 2015/006261 and U.S. Pat. No. 6,294,122, thedisclosures of which are appended hereto as appendices A and Brespectively and incorporated herein by reference as if fully set forthherein.

The second controller can include instructions that control positioningof the valve pin at one or more selected positions between the gateclosed position and the gate open position for a selected period of timesubsequent to movement of the valve pin from the gate closed positiontoward the gate open position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side schematic view of a prior art injection molding systemin which an injection molding machine (IMM) includes a stock or standardIMM controller or signal generator that sends a standard IMM controllersignal to the solenoid of a directional flow control valve that directsthe position of the valve to move between a valve gate closed and valvegate open position.

FIG. 2 is a side schematic view of one embodiment of an injectionmolding system according to the invention where the valve gates includean electrically powered or electric motor containing actuator, thesystem including a machine signal converter that receives a standardsignal generated by an injection machine controller converts the signalto a control signal compatible with the signal receptor of theelectrically powered actuators used in the system, the converter routingthe converted signal to the actuator processor.

FIG. 2A is a generic schematic diagram of an arrangement of signalcommunications between an injection molding machine controller, sensors,a signal converter and electric actuators or the interface of aproportional directional control valve.

FIG. 2B is a schematic diagram of an arrangement of signalcommunications between an injection molding machine controller, positionsensors, a signal converter and electric actuators.

FIG. 2C is a schematic diagram of an arrangement of signalcommunications between an injection molding machine controller, positionsensors, a signal converter and the interfaces of proportionaldirectional hydraulic control valves.

FIG. 2D is a schematic diagram of an arrangement of signalcommunications between an injection molding machine controller, positionsensors, a signal converter and the interfaces of proportionaldirectional pneumatic control valves.

FIG. 3 is a side schematic view of another embodiment of an injectionmolding system according to the invention where the valve gates includea proportional directional control valve, the system including a machinesignal converter that receives a standard signal generated by aninjection machine controller, converts the signal to a control signalcompatible with the signal receptor of the proportional directionalcontrol valves used in the system, the converter sending the convertedsignal to the proportional directional control valves.

FIGS. 3A-3B show tapered end valve pin positions at various times andpositions between a starting closed position as in FIG. 3A and variousupstream opened positions, RP representing a selectable path length overwhich the velocity of withdrawal of the pin upstream from the gateclosed position to an open position is reduced (via a controllable flowrestrictor) relative to the velocity of upstream movement that the valvepin would normally have over the uncontrolled velocity path FOV when thepneumatic pressure is normally at full pressure and pin velocity is atits maximum.

FIGS. 4A-4B show a system having a valve pin that has a cylindricallyconfigured tip end, the tips ends of the pins being positioned atvarious times and positions between a starting closed position as inFIG. 4A and various upstream opened positions, RP wherein RP representsa path of selectable length over which the velocity of withdrawal of thepin upstream from the gate closed position to an open position isreduced (via a controllable flow restrictor or electric actuator)relative to the velocity of upstream movement that the valve pin wouldnormally have over the uncontrolled velocity path FOV when the pneumaticpressure of a pneumatic actuator is normally at full pressure and pinvelocity is at its maximum.

FIGS. 5A-5B show examples of downstream and upstream drive pin positionprotocols. FIG. 5A shows a protocol for driving a pin beginning from amaximum upstream position at a full velocity downstream to a partiallygate open position where the tip end of the pin is disposed at about 4mm from the gate resulting in reduced injection fluid flow and finallydriven downstream from the 4 mm position at a reduced velocity to thegate closed position. In the FIG. 5A embodiment the tip end of the pinis held or maintained in the partially gate open 4 mm position for aselected period of time from about 0.15 and about 0.26 seconds. FIG. 5Bshows a protocol for driving a pin from gate closed downstream upstreamat a reduced velocity to a partially gate open position where the tipend of the pin is disposed at about 2.5 mm from the gate resulting inreduced injection fluid flow through the gate and finally drivenupstream to a maximum upstream position at either a reduced velocity(shown in solid line) or at full velocity (shown in dashed line).

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a conventional pneumatically (or hydraulically) drivensystem 10 with a central nozzle 22 feeding molten material 18 from aninjection molding machine IMM through a main inlet 18 a to adistribution channel 19 of a manifold 40. The IMM typically comprises abarrel (not shown) and a controllably rotatably drivable or driven screwBS that initiates and ends an injection cycle at selected points in timewhen the screw BS is rotatably driven to generate flow of injectionfluid 18. The beginning of an injection cycle is typically defined at aselected point in time when the screw BS is initially rotated from astandstill position or at a time that occurs shortly after the time whenthe screw BS is initially begun rotating. The end of the cycle istypically defined by a time at which the screw BS is stopped fromrotating following and after the selected time that defines thebeginning of the cycle when the screw BS is drivably rotated. Thedistribution channel 19 commonly feeds three separate nozzles 20, 22, 24which all commonly feed into a common cavity 30 of a mold 33. One of thenozzles 22 is controlled by fluid driven actuator 940 f and arranged soas to feed into cavity 30 at an entrance point or gate that is disposedat about the center 32 of the cavity. As shown, a pair of lateralnozzles 20, 24 feed into the cavity 30 at gate locations that are distal34, 36 to the center gate feed position 32.

As shown in FIG. 1 the injection cycle is a cascade process whereinjection is effected in a sequence from the center nozzle 22 first andat a later predetermined time from the lateral nozzles 20, 24. Theinjection cycle is started by first opening the pin 1040 of the centernozzle 22 and allowing the fluid material 100 (typically polymer orplastic material) to flow up to a position the cavity just before 100 bthe distally disposed entrance into the cavity 34, 36 of the gates ofthe lateral nozzles 24. After an injection cycle is begun, the gate ofthe center injection nozzle 22 and pin 1040 is typically left open onlyfor so long as to allow the fluid material 100 b to travel to a positionjust past 100 p the positions 34, 36. Once the fluid material hastravelled just past 100 p the lateral gate positions 34, 36, the centergate 32 of the center nozzle 22 is typically closed by pin 1040 as shownin FIGS. 1B, 1C, 1D and 1E. The lateral gates 34, 36 are then opened byupstream withdrawal of lateral nozzle pins 1041, 1042. As describedbelow, the rate of upstream withdrawal or travel velocity of lateralpins 1041, 1042 is controlled as described below. The center gate 32 andassociated actuator 940 f and valve pin 1040 can remain open at, duringand subsequent to the times that the lateral gates 34, 36 are openedsuch that fluid material flows into cavity 30 through both the centergate 32 and one or both of the lateral gates 34, 36 simultaneously. Whenthe lateral gates 34, 36 are opened and fluid material NM is allowed tofirst enter the mold cavity into the stream 102 p that has been injectedfrom center nozzle 22 past gates 34, 36, the two streams NM and 102 pmix with each other. If the velocity of the fluid material NM is toohigh, such as often occurs when the flow velocity of injection fluidmaterial through gates 34, 36 is at maximum, a visible line or defect inthe mixing of the two streams 102 p and NM will appear in the finalcooled molded product at the areas where gates 34, 36 inject into themold cavity. By injecting NM at a reduced flow rate for a relativelyshort period of time at the beginning when the gate 34, 36 is firstopened and following the time when NM first enters the flow stream 102p, the appearance of a visible line or defect in the final moldedproduct can be reduced or eliminated.

The rate or velocity of upstream and downstream travel of pins 1041,1042 starting from either the gate closed position or the fully openupstream position is controlled via an actuator controller 16 whichcontrols the rate and direction of flow of pneumatic or hydraulic fluidfrom the drive system 14 to the actuators 940 f, 941 f, 942 f. Apredetermined profile of metered drive fluid pressure or a profile ofsensed injection fluid pressure or temperature sensed by a sensor SNthat senses the fluid within the nozzle channel 42, 44, 46 or a profileof sensed pin or actuator position or a profile of injection fluidpressure or temperature sensed within the mold cavity by a cavity sensorSC or a profile of metered drive fluid pressure versus elapsed time canbe input into the actuator controller 16 as the basis for controllingupstream and downstream travel of the valve pin(s) 1041 et al. at one ormore selected velocities over the course of travel of the valve pinthrough the stroke length either upstream or downstream. For example theactuator controller 16 can include instructions that instruct the drivemembers of the actuators to move the actuators at a reduced velocityrelative to one or more selected higher velocities of withdrawal. Thehigher velocity is typically selected to be the highest velocity atwhich the system is capable of driving the actuators. Typically, theinstructions instruct the actuators to move the valve pins upstream fromthe gate closed position at a reduced velocity over the course of travelwhere the tip end of the valve pin restricts the flow of injection fluid18 to less than the flow would otherwise be if the valve pin weredisposed fully upstream, the restriction occurring as a result of thetip end of the valve pin restricting the size of the flow path oropening at or near the gate 32, 34, 36 to a size that is less than thesize of the opening or flow path would otherwise be if the valve pinwere disposed fully upstream of the gate 32, 34, 36.

The actuator controller 16 receives a signal in real time from apressure sensor 603 (or 605, 607) disposed in the drive fluid linecommunicating with the exit of the metering valve 600, the signal beingindicative of the reduced drive fluid pressure in line 703 (or 705,707). The actuator controller 16 instructs the valve 600 to move to adegree of openness that causes the fluid pressure in the line to matchthe pressure of the predetermined profile at any given point in time orpin position along the pressure versus time profile or pressure versusposition profile. The pressure in the exit line of the metering valve600 is proportional and corresponds to the velocity of withdrawalmovement of the actuator 941 f (940 f, 942 f) and associated valve pin1041 (1040, 1042).

As used in this application with regard to various monitoring andcontrol systems, the terms “controller,” “component,” “computer” and thelike are intended to refer to a computer-related entity, eitherhardware, a combination of hardware and software, software, or softwarein execution. For example, a component or controller may be, but is notlimited to being, a process running on a processor, a processor, anobject, an executable, a thread of execution, a program, and/or acomputer. By way of illustration, both an application running on aserver and the server can be a component. One or more components mayreside within a process and/or thread of execution and a component maybe localized on one computer and/or distributed between two or morecomputers.

Claimed methods of the present invention may also be illustrated as aflow chart of a process of the invention. While, for the purposes ofsimplicity of explanation, the one or more methodologies shown in theform of a flow chart are described as a series of acts, it is to beunderstood and appreciated that the present invention is not limited bythe order of acts, as some acts may, in accordance with the presentinvention, occur in a different order and/or concurrent with other actsfrom that shown and described herein. For example, those skilled in theart will understand and appreciate that a methodology couldalternatively be represented as a series of interrelated states orevents, such as in a state diagram. Moreover, not all illustrated actsmay be required to implement a methodology in accordance with thepresent invention.

In various embodiments of the invention disclosed herein, the term“data” or the like means any sequence of symbols (typically denoted “0”and “1”) that can be input into a computer, stored and processed there,or transmitted to another computer. As used herein, data includesmetadata, a description of other data. Data written to storage may bedata elements of the same size, or data elements of variable sizes. Someexamples of data include information, program code, program state,program data, other data, and the like.

As used herein, computer storage media or the like includes bothvolatile and non-volatile, removable and non-removable media for storageof information such as computer-readable instructions, data structures,program modules, or other data. Computer storage media includes RAM,ROM, EEPROM, FLASH memory or other memory technology, CD-ROM, digitalversatile disc (DVDs) or other optical disk storage, magnetic cassettes,magnetic tape, magnetic disk storage or other magnetic storage devices,or any other medium which can be used to store desired information andwhich can be accessed by the computer.

The methods described herein may be implemented in a suitable computingand storage environment, e.g., in the context of computer-executableinstructions that may run on one or more processors, microcontrollers orother computers. In a distributed computing environment (for example)certain tasks are performed by remote processing devices that are linkedthrough a communications network and program modules may be located inboth local and remote memory storage devices. The communications networkmay include a global area network, e.g., the Internet, a local areanetwork, a wide area network or other computer network. It will beappreciated that the network connections described herein are exemplaryand other means of establishing communications between the computers maybe used.

A computer may include one or more processors and memory, e.g., aprocessing unit, a system memory, and system bus, wherein the system buscouples the system components including, but not limited to, the systemmemory and the processing unit. A computer may further include diskdrives and interfaces to external components. A variety ofcomputer-readable media can be accessed by the computer and includesboth volatile and nonvolatile media, removable and nonremovable media. Acomputer may include various user interface devices including a displayscreen, touch screen, keyboard or mouse.

A “controller,” as used herein also refers to electrical and electroniccontrol apparatus that comprise a single box or multiple boxes(typically interconnected and communicating with each other) thatcontain(s) all of the separate electronic processing, memory andelectrical signal generating components that are necessary or desirablefor carrying out and constructing the methods, functions and apparatusesdescribed herein. Such electronic and electrical components includeprograms, microprocessors, computers, PID controllers, voltageregulators, current regulators, circuit boards, motors, batteries andinstructions for controlling any variable element discussed herein suchas length of time, degree of electrical signal output and the like. Forexample a component of a controller, as that term is used herein,includes programs, controllers and the like that perform functions suchas monitoring, alerting and initiating an injection molding cycleincluding a control device that is used as a standalone device forperforming conventional functions such as signaling and instructing anindividual injection valve or a series of interdependent valves to startan injection, namely move an actuator and associated valve pin from agate closed to a gate open position. In addition, although fluid drivenactuators are employed in typical or preferred embodiments of theinvention, actuators powered by an electric or electronic motor or drivesource can alternatively be used as the actuator component.

As shown in the conventional system of FIG. 1, the injection moldingmachine IMM includes its own internal manufacturer supplied machinecontroller that generates standardized beginning of cycle gate closedand end of cycle gate open and gate closed machine voltage signals VStypically 0 volts for gate open and 24 volts for gate open (or 0 voltsand 120 volts respectively). The standardized machine voltage signals VSare typically sent either directly to the solenoids of a masterdirectional control valve 12 (that controls the direction of flow ofactuator drive fluid into or out of the drive chambers of all of theplurality of fluid driven actuators (940 f, 941 f, 942 f) to cause thedirectional control valve 12 (DCV) to move to a gate closed or gate openactuator drive fluid flow position. Or, the same standardized voltagesignals VSC can be sent to the directional control valve 12 via theactuator controller 16 which generates the same standardized voltagesignals VSC as the VS signals in response to receipt from a screwposition sensor SPSR of a machine screw position signal SPS sent by theinjection molding machine IMM to the actuator controller 16, theactuator controller 16 thus generating the same beginning of cycle andend of cycle control voltage signals VSC as the machine IMM canotherwise generate and send VS directly to the directional control valve12. Thus, where conventional standardized directional control valves 12are used, the sending of start of cycle and end of cycle signals can besimplified via electrical or electronic signal connections directly tothe internal signal generator or controller contained within theinjection molding machine.

Electrically powered actuators or electric motors and proportionaldirectional control valves cannot directly receive and utilize astandardized 0 volt (gate closed), 24 volt (gate open) or 0 volt (gateclosed) 120 volt (gate open) signals generated by the start and stopcycle controller or signal generator that is typically included in aconventional injection molding machine.

As shown in a generic schematic form in FIG. 2A, a system 10 accordingto the invention incorporates a signal converter 1500 that can receivesstandardized injection machine generated start of cycle and end of cyclesignals VS (such as 0 volts, 24 volts or 120 volts) and converts thereceived standardized signal VS to an output power signal MOCPS or PDCVSthat is compatible for receipt and use by an electric motor or aproportional direction control valve power signal. The two differentactuator based systems, namely electric motor and proportionaldirectional control valve, are shown together in the generic FIG. 2A forillustration purposes only. More typically, a practical implementationof a system as shown in FIG. 2A would be such that the converter 1500would contain a single microcontroller and an interconnected driver thatis configured to work with one or the other of an electric actuatorbased system or a proportional directional control valve system.

FIG. 2 shows an electric actuator based system in simplified schematicform. As shown in FIG. 2, electric actuators 940 e, 941 e, 942 e eachhave a rotating rotor 940 r, 941 r, 942 r that is driven by electricalpower (typically delivered via the converter 1500) one or more of theprecise polarity, amplitude, voltage and strength of which is controlledfor input to the motors by actuator controller 16 and the programcontained in the actuator controller 16. The rotating rotors 940 r, 941r, 942 r are interconnected to a translationally movable shaft or othersuitable connecting devices 940 c, 941 c, 942 c that interconnect thevalve pins 1040, 1041, 1042 to the driven rotors 940 r, 941 r, 942 r. Atypical interconnection between a shaft driven by a rotor and the headof a valve pin is shown in U.S. Reexamination Certificate 6,294,122 C1and U.S. Pat. No. 9,492,960 the disclosures of which are incorporatedherein by reference in their entirety as if fully set forth herein.

FIG. 2 illustrates an example of a system 10 according to the inventionhaving a plurality of electric power driven actuators 940 e, 941 e, 942e, with a central nozzle 22 feeding molten material 18 from an injectionmolding machine IMM through a main inlet 18 a from a barrel of theinjection molding machine IMM to a distribution channel 19 of a manifold40. As in the conventional system of FIG. 1 in the FIGS. 2, 3 systemsthe IMM typically comprises a barrel (not shown) and a controllablyrotatably drivable or driven screw BS disposed within the barrel togenerate a pressurized supply of injection fluid 18 the pressure ofwhich can be detected by a barrel pressure sensor BPSR which can send asignal indicative of barrel pressure to a controller 16 for use incontrolling positioning and velocity of the valve pin 1040, 1041, 1042.The screw BS of the IMM initiates and ends an injection cycle atselected points in time when rotation of the screw BS is started andstopped. The beginning of an injection cycle is typically defined at afirst selected point in time when the screw BS is initially rotated froma standstill position or at a time that occurs shortly after the timewhen the screw is initially rotated. The end of the cycle is typicallydefined by a selected second time following and after the first selectedtime at which second time the screw is stopped from rotating andinjection fluid 18 is stopped from being injected into the heatedmanifold 40.

The distribution channel 19 commonly feeds three separate nozzles 20,22, 24 which all commonly feed into a common cavity 30 of a mold 33. Oneof the nozzles 22 is controlled by an electric motor actuator 940 e andarranged so as to feed into cavity 30 at an entrance point or gate thatis disposed at about the center 32 of the cavity. As shown, a pair oflateral nozzles 20, 24 feed into the cavity 30 at gate locations thatare distal 34, 36 to the center gate feed position 32.

As with the system of FIG. 1, an injection cycle using the systems ofFIGS. 2, 3 is typically are used to carry out a cascade or sequentialvalve gate process where injection is effected in a sequence from thecenter nozzle 22 first and at later predetermined times from the lateralnozzles 20, 24. The cascade process is discussed in detail as an exampleonly, the invention encompassing configurations and protocols where asingle valve pin and valve gate inject into a single cavity.

Also as with the FIG. 1 system, the FIGS. 2, 3 systems 10 include anactuator controller 16 that typically includes a program that converts astandard voltage signal (such as 0V, 24V, 120V) received from aninjection machine controller MC into an instruction signal IS that iscompatible with, receivable and interpretable by a motor driver MD tocause the motor driver MD to generate a motor operating control powersignal MOCPS that signals the start of an injection cycle and the end ofinjection cycle, the start typically being a power signal that drivesthe motor to withdraw the valve pin 1040, 1041, 1042 from a gate closedposition and the end being a power signal that drives the motor to drivethe valve pin from an upstream position to a gate closed position. Thecontroller 16 can include a program with instructions that can move anddrive the valve pin to and along any predetermined position or velocityprofile including at reduced velocities as described above. Reducedvelocity in the case of the FIG. 2 system means a velocity that is lessthan the maximum velocity at which the electric actuator is capable ofdriving the pin, typically less than about 75% of maximum and moretypically less than about 50% of maximum velocity whether upstream ordownstream.

The actuator controller 16 typically includes additional instructionsthat can instruct a valve pin 1041, 1042, 1040 to be driven eitherupstream or downstream starting from either a fully closed downstream ora fully upstream, gate open position at one or more reduced upstream orreduced downstream velocities over at least the beginning portion of theupstream path of travel of the valve pins 1040, 1041, 1042 or the latterportion of the downstream path of travel of the valve pins toward thegates 32, 34, 36 where the tip end 1142 of the pin 1041 restricts flowof the injection fluid through the gate RP, RP2, RP3 such as shown inFIGS. 3A, 3B, 4A, 4B. Reduced upstream velocity (beginning from theclosed position) or reduced downstream velocity (typically occurring atthe end of the downstream length of the downstream stroke) of a valvepin 1041, FIGS. 3A, 3B, 4A, 4B can serve to lessen the degree ofdownward flow of injection fluid at the beginning of a cycle or downwardforce DF, FIGS. 3B, 4B, exerted by the tip end 1142 of the pin on theinjection fluid 1153 f, FIGS. 3B, 4B, that is forcibly pushed throughthe gate and into the cavity 1153 c, FIGS. 3A, 4A, when the tip end ofthe valve pin travels downstream to a position where the tip end closesthe gate, FIGS. 3A, 4A. Such reduced force DF exerted on the injectionfluid 1153 g at the very beginning or end portion of travel RP, RP2 ofthe injection cycle at or near the entrance 34 to the cavity of the moldthus reduces the likelihood of a blemish or artifact being formed on thepart that is formed within the cavity at the gate area 34.

In one embodiment, an electric actuator 940 e, 941 e, 942 e is drivablyinterconnected to a valve pin 1040, 1041, 1042 in an arrangement whereinthe electric motor drives the valve pin along the axis A, FIGS. 3A, 4A,of the valve pin and drives the tip end 1142 of the valve pin between afirst position where the tip end of the valve pin obstructs the gate 34to prevent the injection fluid from flowing into the cavity, a secondposition upstream of the first position RP, RP2, RP3 wherein the tip end1142 of the valve pin restricts flow 1153 of the injection fluid alongat least a portion of the length of the drive path extending between thefirst position and the second position, and a third maximum upstreamposition FOP where the injection fluid material flows freely withoutrestriction from the tip end 1142 of the pin through the first gate.

The electric motor 62 can be configured and arranged relative to thevalve pin 1041 such that the driven rotor 154, 174 and shaft 158, 162components of the motor 62, FIG. 7A are axially aligned with the axis Aof the valve pin. Alternatively, a motor 62 configuration can be usedsuch as in U.S. Pat. No. 9,492,960 where the driven rotor and shaft 61components are arranged at an angle to the axis A, FIGS. 3A, 4A.

In an embodiment such as shown in FIGS. 2, 3 an injection cycle can bestarted by first opening the pin 1040 of the center nozzle 22, FIG. 1A,and allowing the fluid material 100 (typically polymer or plasticmaterial) to flow up to a position the cavity just before 100 b thedistally disposed entrance into the cavity 34, 36 of the gates of thelateral nozzles 24, 20. After an injection cycle is begun, the gate ofthe center injection nozzle 22 and pin 1040 is typically left open onlyfor so long as to allow the fluid material 100 b to travel to a positionjust past 100 p the positions 34, 36. Once the fluid material hastravelled just past 100 p the lateral gate positions 34, 36, the centergate 32 of the center nozzle 22 is typically closed by pin 1040 as shownin FIGS. 1B, 1C, 1D and 1E. The lateral gates 34, 36 are then opened byupstream withdrawal of lateral nozzle pins 1041, 1042. As describedbelow, the rate of upstream withdrawal or travel velocity of lateralpins 1041, 1042 is controlled as described below.

In alternative embodiments, the center gate 32 and associated actuator940 e, 940 p and valve pin 1040 can remain open at, during andsubsequent to the times that the lateral gates 34, 36 are opened suchthat fluid material flows into cavity 30 through both the center gate 32and one or both of the lateral gates 34, 36 simultaneously. When thelateral gates 34, 36 are opened and fluid material NM is allowed tofirst enter the mold cavity into the stream 102 p that has been injectedfrom center nozzle 22 past gates 34, 36, the two streams NM and 102 pmix with each other. If the velocity of the fluid material NM is toohigh, such as often occurs when the flow velocity of injection fluidmaterial through gates 34, 36 is at maximum, a visible line or defect inthe mixing of the two streams 102 p and NM will appear in the finalcooled molded product at the areas where gates 34, 36 inject into themold cavity. By injecting NM at a reduced flow rate for a relativelyshort period of time at the beginning when the gate 34, 36 is firstopened and following the time when NM first enters the flow stream 102p, the appearance of a visible line or defect in the final moldedproduct can be reduced or eliminated.

A signal converter 1500, FIGS. 2, 3 is provided that enables a user toconnect the standardized voltage signal output (VS, VSC) of aconventional IMM controller to the input of the electric motors 940 e,941 e, 942 e, FIGS. 2, 3 in the same manner that the user interconnectedan IMM controller in a conventional system as in FIG. 1 to DCVs. Thesignal converter 1500 of the FIGS. 2, 3 systems receives and convertsreceived IMM voltage signals (such as 0 volts, 24 volts, 120 volts) tocontrol signals (MOCPS or PDCVS that operate to begin cycle and endcycle). As shown in FIGS. 2. 2A, 3 the standardized voltage signals VScan be alternatively generated by an HPU (hydraulic power unit) that isphysically separate but interconnected to the machine controller MC, theHPU unit, FIGS. 2, 2A, 2B, 2C, 3 receiving a barrel screw positionsignal SPS from the machine controller and generating therefrom acorresponding standardized VS signal that is in turn sent to thecontroller 16 for conversion to an instruction signal IS usable byeither a motor driver MD, FIG. 2A, or by a proportional directionalvalve driver HVD, PVD, FIGS. 2B, 2C to drive either a motor or aproportional directional valve to initiate and end an injection cycle.

Thus the standard start and stop control signals generated by an IMM(VS, VSC) can operate in conjunction with the converter 1500 to instructeither the electric actuators, 940 e, 941 e, 942 e or the fluid drivenactuators 940 p, 941 p, 942 p, to at least initiate or begin aninjection cycle (such as by instructing the actuators 940 e, 941 e, 942e, 940 p, 941 p, 942 p to drive a valve pin upstream from a gate closedposition) and to end or stop an injection cycle (such as by instructingthe actuators 940 e, 941 e, 942 e, 940 p, 941 p, 942 p to drive a valvepin downstream from a gate open position into a gate closed position).

Most preferably the physical or mechanical electric signal connectorsthat are typically used to connect a wire or cable from the IMM (ormachine controller MC) to the signal conversion device 1500, are thesame physical or mechanical connectors that are used in conventionalsystems to connect the IMM (or machine controller MC) to the DCVs of aconventional system as described with reference to FIG. 1.

As shown in FIGS. 2, 2A, 2B, 2C the signal output VS of the IMM can beconnected directly to signal converter 1500 which converts the VS signalinto a motor open close power signal MOPCS or a proportional directionalcontrol valve signal PDCVS that is compatible with and processable bythe motors 940 e, 941 e, 942 e or the proportional directional controlvalves V, V1, V2. Alternatively, the signal output of the IMM of themachine controller MC of the FIG. 2 embodiment can comprise a barrelscrew position signal SPS that is sent to an intermediate HPU unit by ascrew position sensor SPSR.

The MOCPS and PDCVS signals include signals that correspond to the VSsignals that operate to affect the beginning and end of an injectioncycle.

Typically the FIG. 2 system 10 includes one or more position sensors,950, 951, 952 or other sensors, SN, SC that detect a selected conditionof the injection fluid 18 in one or more of the manifold fluid flowchannel 19, a nozzle flow channel 42, 44, 46 or in the cavity 30 of themold 33.

The actuator controller 16 can include a program that receives andprocesses a real time signal indicative of a condition of the injectionfluid 18 or a component of the apparatus (10) such as rotationalposition of a rotor 940 r, 941 r, 942 r or axial linear position of avalve pin 1040, 1041, 1042. The real time signals sent to and receivedby the actuator controller 16 are generated by one or more of positionsensors 950, 951, 952 or fluid condition sensors SN, SC. The sensorsdetect and send a signal to the actuator controller that is typicallyindicative of one or more of rotational position (sensors 950, 951, 952)of a rotor 940 r, 941 r, 942 r or of linear axial position of a valvepin 1040, 1041, 1042. The fluid condition sensors typically comprise oneor more of a pressure or temperature sensor SN that senses injectionfluid 18 within a manifold channel 19 or a nozzle channel 42, 44, 46 orsenses pressure or temperature of the injection fluid SC within thecavity 30 of the mold 33.

The actuator controller 16 can include a program that processes thereceived signal(s) from one or more of the sensors 950, 951, 952, SN, SCaccording to a set of instructions that use the received signals as avariable input or other basis for controlling one or more of theposition or velocity of the actuators 940 e, 941 e, 942 e or theirassociated valve pins 1040, 1041, 1042 throughout all or selectedportion of the duration of an injection cycle or all or a portion of thelength of the upstream or downstream stroke of the actuators 940 e, 941e, 942 e.

As shown the controller 16 can be included within and comprise acomponent of the converter 1500, FIGS. 2, 2A, 2B, 2C, 3. Where theconverter 1500 includes a controller 16 that includes position andvelocity control instructions, the converter 1500 can thus send itsmachine open close power signals MOCPS (or valve open close signalsPDCVS) together with position velocity signals (PVS) to either theelectric actuators 940 e, 941 e, 942 e or proportional directionalcontrol valves V, V1, V2. The control signals MOCPS and PDCVS thusinclude a signal that has been converted from and corresponds to one orthe other of the converted VS signals received by the converter 1500from the IMM controller MC or the HPU. The position or velocity controlsignals PVS can control the position or velocity of the valve pinaccording to any predetermined profile of pin position or velocityversus time of injection cycle. The form, format, intensity andfrequency of the MOCPS, PDCVS and PVS signals are compatible with thesignal receiving interface of the electric actuators 940 e, 941 e, 942 eor valves V, V1, V2.

In an alternative embodiment as shown in FIG. 3, the system 10 utilizes“proportional” directional control valves, V, V1, V2 that can controlthe movement of the fluid driven actuators 940 p, 941 p, 942 pthroughout the entire injection cycle according to a profile ofpositions or velocities. Proportional directional control valves can beoperated to effect positioning of the actuators to both the start ofcycle and end of cycle positions of the actuators 940 p, 941 p, 942 pand also to control the rate and position of travel of the actuatorsover the entire course of an injection cycle and over the entire path oftravel of the actuators 940 p, 941 p, 942 p and their associated valvepins 1040, 1041, 1042 through the entire length of the upstream anddownstream stroke(s) of the actuators. The system 10 of the FIG. 3embodiment uses a signal converter 1500 in a manner similar to the useof the converter 1500 in the FIG. 2 electric actuator 940 e, 941 e, 942e embodiment. Thus, in the FIG. 3 embodiment, the IMM controller MCeither sends a conventional standardized VS signal to the signalconverter 1500 (or to an HPU) which in turn sends a proportionaldirectional control valve signal PDCVS to the signal receiving interfaceor driver HVD, FIG. 2C, of a proportional directional control valve V,V1, V2 to effect start of cycle and end of cycle movement of theactuators 940 p, 941 p, 942 p.

More typically in an embodiment as shown in FIG. 3 that usesproportional directional control valves V, V1, V2, the system 10includes one or more sensors, SN, SC that detect a selected condition ofthe injection fluid 18 in one or more of a manifold fluid flow channel19, a nozzle flow channel 42, 44, 46 or in the cavity 30 of the mold 33.The IMM controller MC of the FIG. 3 system can be adapted to send ascrew position signal SPS to the intermediate HPU which in turn sends astandardized VS signal to signal converter 1500. As in the FIG. 2embodiment, the signal converter 1500 of FIG. 3 typically includes anactuator controller 16 that receives and processes a real time signalfrom one or more of sensors 950, 951, 952, SN, SC, the sensors detectingand sending a signal to the actuator controller 16 that is indicative ofone or more of position of a piston or shaft of an actuator 940 p, 941p, 942 p, or a valve pin 1040, 1041, 1042, pressure or temperature(sensors SN) of the injection fluid 18 within a manifold channel 19 ornozzle channel 42, 44, 46 or pressure or temperature (sensor SC) of theinjection fluid within the cavity 30 of the mold 33. The actuatorcontroller 16 preferably includes a program that processes the receivedsignal(s) from one or more of the sensors 950, 951, 952, SN, SCaccording to a set of instructions that use the received signals as avariable input or other basis for controlling one or more of theposition or velocity of the actuators 940 p, 941 p, 942 p or theirassociated valve pins 1040, 1041, 1042 throughout all or selectedportion of the duration of an injection cycle or all or a portion of thelength of the upstream or downstream stroke of the actuators 940 p, 941p, 942 p. As shown, the controller 16 sends its instruction signals ISto the signal receiving interface or driver HVD, FIG. 2C, of aproportional directional control valve V, V1, V2 which in turn sends thevalve control signal PDCVS to the valves V, V1, V2. The control signalPDCVS includes a signal that has been converted from and corresponds tothe standardized VS signals received by the converter 1500 from the IMMcontroller MC or HPU. The control signal PDCVS further includes positionor velocity control signals generated by the program and instructionscontained within the actuator controller 16. The form, format, intensityand frequency of the PDCVS signal is compatible with the signalreceiving interface of the proportional directional control valves V,V1, V2.

Preferably, the valve pin 1040, 1041, 1042 and their associated gatesare configured or adapted to cooperate with each other to restrict andvary the rate of flow of fluid material 1153, FIGS. 3A-3B, 4A-4B overthe course of travel of the tip end of the valve pin through therestricted velocity path RP. Most typically as shown in FIGS. 3A, 3B theradial tip end surface 1155 of the end 1142 of pin 1041, 1042 is conicalor tapered and the surface of the gate 1254 with which pin surface 1155is intended to mate to close the gate 34 is complementary in conical ortaper configuration. Alternatively as shown in FIGS. 4A, 4B, the radialsurface 1155 of the tip end 1142 of the pin 1041, 1042 can becylindrical in configuration and the gate can have a complementarycylindrical surface 1254 with which the tip end surface 1155 mates toclose the gate 34 when the pin 1041 is in the downstream gate closedposition. In any embodiment, the outside radial surface 1155 of the tipend 1142 of the pin 1041 creates restricted a restricted flow channel1154 over the length of travel of the tip end 1142 through and alongrestricted flow path RP that restricts or reduces the volume or rate offlow of fluid material 1153 relative to the rate of flow when the pin1041, 1042 is at a full gate open position, namely when the tip end 1142of the pin 1041 has travelled to or beyond the length of the restrictedflow path RP.

In one embodiment, as the tip end 1142 of the pin 1041 continues totravel upstream from the gate closed GC position (as shown for examplein FIGS. 3A, 4A) through the length of the RP path (namely the pathtravelled for the predetermined amount of time), the rate of materialfluid flow 1153 through restriction gap 1154 through the gate 34 intothe cavity 30 continues to increase from 0 at gate closed GC position toa maximum flow rate when the tip end 1142 of the pin reaches a positionFOP (full open position), where the pin is no longer restricting flow ofinjection mold material through the gate. In such an embodiment, at theexpiration of the predetermined amount of time when the pin tip 1142reaches the FOP (full open) position, the pin 1041 can be immediatelydriven by the actuator system at maximum velocity FOV (full openvelocity) typically such that the restriction valve 600 is opened tofull 100% open.

In embodiments, where the tip 1142 has reached the end of restrictedflow path RP2 and the tip 1142 is not necessarily in a position wherethe fluid flow 1153 is not still being restricted, the fluid flow 1153can still be restricted to less than maximum flow when the pin hasreached the changeover position COP2 where the pin 1041 is driven at ahigher, typically maximum, upstream velocity FOV. In the examples shownin the FIGS. 3B, 4B examples, when the pin has travelled thepredetermined path length at reduced velocity and the tip end 1142 hasreached the changeover point COP, the tip end 1142 of the pin 1041 (andits radial surface 1155) no longer restricts the rate of flow of fluidmaterial 1153 through the gap 1154 because the gap 1154 has increased toa size that no longer restricts fluid flow 1153 below the maximum flowrate of material 1153. Thus in one of the examples shown in FIG. 3B themaximum fluid flow rate for injection material 1153 is reached at theupstream position COP of the tip end 1142. In another example shown inFIG. 3B 4B, the pin 1041 can be driven at a reduced velocity over ashorter path RP2 that is less than the entire length of the restrictedmold material flow path RP and switched over at the end COP2 of theshorter restricted path RP2 to a higher or maximum velocity FOV.

In another alternative embodiment, shown in FIG. 4B, the pin 1041 can bedriven and instructed to be driven at reduced or less than maximumvelocity over a longer path length RP3 having an upstream portion URwhere the flow of injection fluid mold material is not restricted butflows at a maximum rate through the gate 34 for the given injection moldsystem. In this FIG. 4B example the velocity or drive rate of the pin1041 is not changed over until the tip end of the pin 1041 or actuator941 has reached the changeover position COP3. In this embodiment, aposition sensor senses either that the valve pin 1041 or an associatedcomponent has travelled the path length RP3 or reached the end COP3 ofthe selected path length and the controller receives and processes suchinformation and instructs the drive system to drive the pin 1041 at ahigher, typically maximum velocity upstream. In another alternativeembodiment, the pin 1041 can be driven at a less than maximum velocitythroughout the entirety of the travel path of the pin during aninjection cycle from the gate closed position GC up to the end-of-strokeEOS position, the actuator controller 16 being programmed to instructthe drive system for the actuator to be driven at one reduced velocityfor an initial path length or period of time and at another less thanmaximum velocity subsequent to the initial reduced velocity path orperiod of time for the remainder of the injection cycle whereby theactuator/valve pin travels at a less than maximum velocity for an entireclosed GC to fully open EOS cycle.

In a typical example FOV is 100 mm/sec. Typically, when the time periodor path length for driving the pin 1041 at reduced velocity has expiredor been reached and the pin tip 1142 has reached the position COP, COP2,the restriction valve 600 is opened to full 100% open velocity FOVposition such that the pins 1041, 1042 are driven at the maximumvelocity or rate of travel that the pneumatic system is capable ofdriving the actuators 941, 942. Alternatively, the pins 1041, 1042 canbe driven at a preselected FOV velocity that is less than the maximumvelocity at which the pin is capable of being driven when therestriction valve 600 is fully open but is still greater than theselected reduced velocities that the pin is driven over the course ofthe RP, RP2 path to the COP, COP2 position.

At the expiration of the predetermined reduced velocity drive time, thepins 1041, 1042 are typically driven further upstream past the COP, COP2position to a maximum end-of-stroke EOS position. The upstream COP, COP2position is downstream of the maximum upstream end-of-stroke EOS openposition of the tip end 1142 of the pin. The length of the path RP orRP2 is typically between about 2 and about 8 mm, more typically betweenabout 2 and about 6 mm and most typically between about 2 and about 4mm. In practice the maximum upstream (end of stroke) open position EOSof the pin 1041, 1042 ranges from about 8 mm to about 18 inches upstreamfrom the closed gate position GC.

The invention includes configurations where a valve pin 1040, 1041, 1042is driven downstream starting from a fully upstream, gate open positionat one or more reduced downstream velocities over at least the latterportion of the downstream path of travel of the pin toward the gatewhere the tip end 1142 of the pin 1041 restricts flow of the injectionfluid through the gate RP, RP2, RP3 such as shown in FIGS. 3A and 4A.Reduced downstream velocity drive of a valve pin 1041, FIGS. 3A, 3B, 4A,4B can serve to lessen the degree of downward force DF, FIGS. 3B, 4B,exerted by the tip end 1142 of the pin on the injection fluid 1153 f,FIGS. 3B, 4B, that is forcibly pushed through the gate and into thecavity 1153 c, FIGS. 3A, 4A, when the tip end of the valve pin travelsdownstream to a position where the tip end closes the gate, FIGS. 3A,4A. Such reduced force DF exerted on the injection fluid 1153 g at thevery end portion of travel RP, RP2 of the injection cycle at theentrance 34 to the cavity of the mold thus reduces the likelihood of ablemish or artifact being formed on the part that is formed within thecavity at the gate area 34.

In one embodiment of a method according the invention, an actuator 940e, 940 f, 940 p, 941 e, 941 f, 941 p, 942 e, 942 p, 942 f is drivablyinterconnected to a valve pin 1040, 1041, 1042 in an arrangement whereinthe actuator drives the valve pin along the axis A, FIGS. 3A, 4A, of thevalve pin and drives the tip end 1142 of the valve pin between a firstposition where the tip end of the valve pin obstructs the gate 34 toprevent the injection fluid from flowing into the cavity, a secondposition upstream of the first position RP, RP2, RP3 wherein the tip end1142 of the valve pin restricts flow 1153 of the injection fluid alongat least a portion of the length of the drive path extending between thefirst position and the second position, and a third maximum upstreamposition FOP where the injection fluid material flows freely withoutrestriction from the tip end 1142 of the pin through the first gate.

Where the actuator comprises an electric actuator, the actuator 940 e,941 e, 942 e can be configured and arranged relative to the valve pin1041 such that the driven rotor and shaft components of the motor, areaxially aligned with the axis A of the valve pin. Alternatively, a motor62 configuration can be used such as in U.S. Pat. No. 9,498,909 wherethe driven rotor and shaft components are arranged at an angle to theaxis A, FIGS. 3A, 4A or the axis of the valve pin 1041 component.

The actuators are operable to drive the valve pin at one or moreintermediate rates of upstream and downstream travel extending betweenzero and a maximum rate of upstream travel and a maximum rate ofdownstream travel, the method comprising selecting a length of travelbetween a maximum upstream position and a predetermined third positionthat is downstream of the maximum upstream position and upstream of thefirst downstream position, and controllably operating the actuator todrive the associated valve pin at one or more high rates of downstreamtravel that are equal to or less than the maximum rate of downstreamtravel when the valve pin is disposed at the maximum upstream positionduring the course of an injection cycle, sensing the position of thevalve pin to determine when the tip end of the valve pin has reached thepreselected downstream position during the course of downstream travel,and controllably operating the actuator to drive the valve pin at one ormore intermediate rates of downstream travel that are less than the oneor more high rates of downstream travel when the tip end of the valvepin has been determined in the step of sensing to have reached thedownstream position to drive the tip end of the valve pin continuouslydownstream from the downstream position to a closed position.

In an alternative pin movement protocol, an example of which is shown inFIGS. 5A, 5B the tip end of the pin 1040, 1041, 1042 is driven eithercontinuously upstream or continuously downstream with the tip end of thepin being held or maintained in a reduced or restricted flow positionintermediate the full open and gate closed positions for some selectedperiod of time during the course of travel between full open and gateclosed, typically at a restricted flow “pack” or “pack pressure”position after the cavity 30 has been substantially already filled withinjection fluid 18 typically after the injection fluid 18 has filled 90%or more of the volume of the cavity. In the FIG. 5A example the pin isheld in an intermediate reduced or restricted flow 4 mm upstream fromgate closed position for between about 0.15 and about 0.26 seconds.Preferably, the actuator controller 16 instructs the valve pin 1041,1042, 1040 to travel either (a) continuously upstream during theupstream travel portion of the cycle rather than follow a drive fluidpressure, pin position or injection fluid pressure profile where the pinmight travel in a downstream direction during the course of the upstreamtravel portion of the injection cycle, or (b) continuously downstreamduring the downstream travel portion of the cycle rather than follow aprofile where the pin travels upstream during the course of thedownstream travel portion of the injection cycle.

What is claimed is:
 1. An injection molding apparatus (10) comprising aninjection molding machine (IMM) having a drivably rotatable barrel screw(BS) that generates an injection fluid (18), a heated manifold (40) thatreceives the injection fluid (18) from the injection molding machine(IMM) and distributes the injection fluid (18) to one or more gates (32,34, 36), a mold (42) having a cavity (30) communicating with the gatesto receive the injection fluid (18), the injection molding machine (IMM)including a machine controller (MC) or control unit (HPU) that generatesone or more direction control valve compatible signals (VPS), whereinthe directional control valve compatible signals (VS) are compatible forreceipt and use by a signal receptor, interface or driver of a standarddirectional control valve (12) to instruct the fluid directional controlvalve (12) to move to a position that routes a source of drive fluid toflow in a direction that drives an interconnected fluid drivableactuator (940 f, 941 f, 942 f) to move in a direction that operates tobegin an injection cycle and to end an injection cycle, a signalconverter (1500) interconnected to the machine controller (MC) orcontrol unit (HPU), the signal converter (1500) being adapted to convertthe directional control valve compatible signals (VPS) to a commandsignal (MOPCS, PDCVS) that is compatible with a signal receptor orinterface of an electrically powered actuator (940 e, 941 e, 942 e) or asignal receptor or interface of a proportional directional control valve(V, V1, V2) that is interconnected to a fluid driven actuator (940 p,941 p, 942 p), wherein the command signals (MOPCS, PDCVS) are convertedby the signal converter (1500) into a form, frequency, power or formatthat is usable by the signal receptor or interface of the electricallypowered actuator (940 e, 941 e, 942 e) or the proportional directionalcontrol valve (V, V1, V2) to respectively cause the electrically poweredactuator (940 e, 941 e, 942 e) or the proportional directional controlvalve (V, V1, V2) to be driven in a direction that operates to eitherbegin an injection cycle or to end an injection cycle.
 2. The apparatusaccording to claim 1 wherein the direction that operates to begin aninjection cycle is a direction that operates to cause the actuator (940e, 941 e, 942 e, 940 p, 941 p, 942 p) or its associated valve pin (1040,1041, 1042) to open a gate (32, 34, 36) and the direction that operatesto end an injection cycle is a direction that causes the actuator (940e, 941 e, 942 e, 940 p, 941 p, 942 p) or its associated valve pin (1040,1041, 1042) to close the gate (32, 34, 36).
 3. The apparatus accordingto claim 1 wherein the direction that operates to begin an injectioncycle is an upstream direction in which the actuator (940 e, 941 e, 942e, 940 p, 941 p, 942 p) or its associated valve pin (1040, 1041, 1042)moves upstream from a gate closed position to an open gate position (32,34, 36) and the direction that operates to end an injection cycle is adownstream direction in which the actuator (940 e, 941 e, 942 e, 940 p,941 p, 942 p) or its associated valve pin (1040, 1041, 1042) movesdownstream from an open gate position to a closed gate position (32, 34,36).
 4. The apparatus according to claim 1 wherein the directionalcontrol valve compatible signals (VPS) comprises a voltage signal ofpredetermined voltage or magnitude indicative of a predeterminedrotational position of the barrel screw (BS) of the injection moldingmachine (IMM) that generates pressurized injection fluid (18) within theapparatus.
 5. The apparatus according to claim 1 wherein the apparatus(10) further comprises one or more sensors (950, 951, 952, SN, SC, SPSR,BPSR) that detect and generate one or more sensor signals indicative ofone or more of rotational or linear position of an actuator (940 e, 941e, 942 e, 940 p, 941 p, 942 p) or its associated valve pin (1040, 1041,1042), pressure or temperature of the injection fluid 18 within a fluidchannel (19) of the manifold (40) or within a nozzle channel (42, 44,46) or within the cavity (30) of the mold (33) or within a barrel of theinjection molding machine (IMM), the apparatus (10) including anactuator controller (16) that receives and uses the one or more sensorsignals in a program that: instructs the actuator (940 e, 941 e, 942 e,940 p, 941 p, 942 p) or its associated valve pin (1040, 1041, 1042) totravel during the course of the injection cycle to positions thatcorrespond to a predetermined profile of injection fluid pressures,linear or rotational pin positions, linear actuator or valve pinpositions, barrel screw positions, barrel pressures or actuator drivefluid pressures or that, instructs the actuator (940 e, 941 e, 942 e,940 p, 941 p, 942 p) or its associated valve pin (1040, 1041, 1042) suchthat the valve pin is withdrawn from a closed gate position upstream ata reduced velocity over a selected path of upstream travel, or that,instructs the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or itsassociated valve pin (1040, 1041, 1042) to travel such that the valvepin is driven downstream at a reduced velocity over a selected path oftravel where a distal tip end of the pin travel from upstream of thegate to a gate closed position, or that, instructs the actuator (940 e,941 e, 942 e, 940 p, 941 p, 942 p) or its associated valve pin (1040,1041, 1042) to travel such that the valve pin is driven upstream ordownstream to an intermediate position between a gate closed positionand a fully upstream position where the valve pin is maintained in theintermediate position for a selected period of time during the course ofthe injection cycle wherein, in the intermediate position, the distaltip end of the valve pin restricts flow of injection of the injection toless than a maximum flow.
 6. A method of beginning and ending aninjection cycle comprising operating an apparatus (10) in accordance toclaim 1 to perform an injection cycle.
 7. A signal converter (1500) forconverting signals generated by an injection molding apparatus (10) thatis comprised of an injection molding machine (IMM) having a drivablyrotatable barrel screw (BS) that generates an injection fluid (18), aheated manifold (40) that receives an injection fluid (18) from theinjection molding machine (IMM) and distributes the injection fluid (18)to one or more gates (32, 34, 36), a mold (42) having a cavity (30)communicating with the gates to receive the injection fluid (18),wherein the injection molding machine (IMM) includes a machinecontroller (MC) or a control unit (HPU) that generates one or moredirectional control valve compatible signals (VPS), wherein thedirection control valve compatible signals (VPS) are compatible for useby a signal receptor, interface or driver of a standard fluiddirectional control valve (12) to instruct the fluid directional controlvalve (12) to move to a position that routes a source of drive fluid toflow in a direction that drives an interconnected fluid drivableactuator (940 f, 941 f, 942 f) to move in a direction that operates tobegin an injection cycle and to move in a direction that operates to endan injection cycle, wherein the signal converter (1500) isinterconnected to the machine controller (MC) or control unit (HPU), thesignal converter (1500) receiving and converting the directional controlvalve compatible signals (VPS) to a command signal (MOPCS, PDCVS) thatis compatible with a signal receptor or interface of an electricallypowered actuator (940 e, 941 e, 942 e) or a signal receptor or interfaceof a proportional directional control valve (V, V1, V2) that drives afluid driven actuator (940 p, 941 p, 942 p), wherein the signalconverter (1500) includes a processor that converts the command signals(MOPCS, PDCVS) into a form, frequency, power or format that is usable bythe signal receptor or interface of the electrically powered actuator(940 e, 941 e, 942 e) or by the signal receptor or interface of theproportional directional control valve (V, V1, V2) to respectively causethe electrically powered actuator (940 e, 941 e, 942 e) or theproportional directional control valve (V, V1, V2) to be driven in adirection that operates to either begin an injection cycle or to end aninjection cycle.
 8. The signal converter according to claim 7 whereinthe direction that operates to begin an injection cycle is a directionthat operates to moves the actuator (940 e, 941 e, 942 e, 940 p, 941 p,942 p) or its associated valve pin (1040, 1041, 1042) to open a gate(32, 34, 36) and the direction that operates to end an injection cycleis a direction that operates to move the actuator (940 e, 941 e, 942 e,940 p, 941 p, 942 p) or its associated valve pin (1040, 1041, 1042) toclose the gate (32, 34, 36).
 9. The signal converter according to claim7 wherein the direction that operates to begin an injection cycle is anupstream direction in which the actuator (940 e, 941 e, 942 e, 940 p,941 p, 942 p) or its associated valve pin (1040, 1041, 1042) movesupstream from a gate closed position to an open gate position (32, 34,36) and the direction that operates to end an injection cycle is adownstream direction in which the actuator (940 e, 941 e, 942 e, 940 p,941 p, 942 p) or its associated valve pin (1040, 1041, 1042) movesdownstream from an open gate position to a closed gate position (32, 34,36).
 10. The signal converter according to claim 7 wherein thedirectional control valve compatible signals (VPS) comprise a voltagesignal of predetermined voltage or magnitude indicative of apredetermined rotational position of the barrel screw (BS) of theinjection molding machine (IMM) that generates pressurized injectionfluid (18) within the apparatus.
 11. The signal converter according toclaim 7 wherein the apparatus (10) further comprises one or more sensors(950, 951, 952, SN, SC, SPSR, BPSR) that detect and generate one or moresensor signals indicative of one or more of rotational or linearposition of an actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) orits associated valve pin (1040, 1041, 1042), pressure or temperature ofthe injection fluid 18 within a fluid channel (19) of the manifold (40)or within a nozzle channel (42, 44, 46) or within the cavity (30) of themold (33) or within a barrel of the injection molding machine (IMM), theapparatus (10) including an actuator controller (16) that receives anduses the one or more sensor signals in a program that: instructs theactuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or its associatedvalve pin (1040, 1041, 1042) to travel during the course of theinjection cycle to positions that correspond to a predetermined profileof injection fluid pressures, linear or rotational pin positions, linearactuator or valve pin positions, barrel screw positions, barrelpressures or actuator drive fluid pressures or that, instructs theactuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or its associatedvalve pin (1040, 1041, 1042) such that the valve pin is withdrawn from aclosed gate position upstream at a reduced velocity over a selected pathof upstream travel, or that, instructs the actuator (940 e, 941 e, 942e, 940 p, 941 p, 942 p) or its associated valve pin (1040, 1041, 1042)to travel such that the valve pin is driven downstream at a reducedvelocity over a selected path of travel where a distal tip end of thepin travel from upstream of the gate to a gate closed position, or that,instructs the actuator (940 e, 941 e, 942 e, 940 p, 941 p, 942 p) or itsassociated valve pin (1040, 1041, 1042) to travel such that the valvepin is driven upstream or downstream to an intermediate position betweena gate closed position and a fully upstream position where the valve pinis maintained in the intermediate position for a selected period of timeduring the course of the injection cycle wherein, in the intermediateposition, the distal tip end of the valve pin restricts flow ofinjection of the injection to less than a maximum flow.
 12. A method ofbeginning and ending an injection cycle comprising operating a signalconverter (1500) in accordance with claim 7 to perform an injectioncycle.
 13. A modular control unit (1500) comprising: a housing (1502)containing an electronic controller (16), multiple input interfaces(1504, 1506), and at least one driver (MD, HVD, PVD), a first inputinterface (1506) configured to receive a valve control signal (VS)specifying valve open or valve closed or start of injection cycle andend of injection cycle, and outputting a data signal (1506 s) indicativethereof to the controller (16); a second input interface (1504)configured to receive a pin position signal (PS) specifying a positionof a valve pin along a continuous path of travel and outputting a datasignal (1504 s) indicative thereof to the controller (16); thecontroller (16) including a processor and computer readable media withinstructions for pre-configured actuated control of valve pin position,wherein the instructions, when executed by the processor, cause theprocessor to generate, based on the data signals (VS, PS) an outputcontrol signal (IS) for controlling valve pin position via at least oneof: a) a hydraulic proportional directional control valve (V, V1, V2),b) a pneumatic proportional directional control valve (P1, P2, P3), andc) an electric motor (940 e, 941 e, 942 e), the at least one driver (MD,HVD, PVD) configured to receive the output control signal from thecontroller and generate a control unit output signal (MOPCS, PDCVS, PVS)that drives at least one of a) the hydraulic proportional directionalcontrol valve (V, V1, V2), b) the pneumatic proportional directionalcontrol valve (P1, P2, P3), and c) the electric motor (940 e, 941 e, 942e) for control movement of the valve pin.
 14. The modular control unit(1500) of claim 13 wherein the pin position signal (PS) is received froma sensor (950, 951, 952) that senses a linear or rotational position ofan actuator (940 e, 940 f) or a valve pin (1040, 1041).
 15. The modularcontrol unit of claim 13 wherein the housing (1502) further contains apower management circuit (1508) that receives an input AC or DC powerinput, and wherein the power management circuit outputs a power signal(1508 s) to the driver (MD, HVD, PVD).
 16. The modular control unit ofclaim 13 adapted for use in an injection molding apparatus wherein: aninjection molding machine (IMM) or a fluid pressure unit (HPU) generatesthe input valve control signal (VS.) specifying valve open and valveclosed or start of injection cycle and end of injection cycle, and aposition sensor (950, 951, 952) generates the input pin position signal(PS).
 17. The modular control unit of claim 13 further comprising a userinterface (1510) for receiving input from a human operator, the inputbeing transmitted to the controller (16) and the input being stored onthe computer readable media.
 18. The modular control unit of claim 13wherein the input is executed by the processor, along with theinstructions, for generating the output control signal.
 19. The modularcontrol unit of claim 13 wherein the output control signal specifiesinstructions for one or more of: calibrating a valve pin positionsensor, specifying a valve pin open or closed position, specifying avalve pin position along the continuous path of travel, and specifying avalve pin velocity.
 20. The modular control unit of claim 13 wherein theinstructions for pre-configured actuated control of valve pin positioncomprise sequential valve gating control parameters.
 21. The modularcontrol unit of claim 13 wherein: the instructions for pre-configuredactuated control of valve pin position comprise simultaneous valvegating control parameters.
 22. A modular injection molding systemcontrol unit (1500) interconnected to an injection molding machine (IMM)controller (MC) comprising: a housing (1502) containing an electroniccontroller (16), one or more input interfaces (1504, 1506), and at leastone driver (MD, HVD, PVD), at least one input interface (1506)configured to receive a valve control signal (VS) specifying valve openand valve closed or start of injection cycle and end of injection cycle,and outputting a data signal (1506 s) indicative thereof to thecontroller (16); the controller (16) including a processor and computerreadable media with instructions for pre-configured actuated control ofvalve pin position, wherein the instructions, when executed by theprocessor, cause the processor to generate, based on the data signal(1506 s) an output control signal (IS) for controlling valve open andvalve closed position or start of injection cycle and end of injectioncycle via at least one of: a) a hydraulic proportional directionalcontrol valve (V, V1, V2), b) a pneumatic proportional directionalcontrol valve (P1, P2, P3), and c) an electric motor (940 e, 941 e, 942e), the at least one driver (MD, HVD, PVD) configured to receive theoutput control signal (IS) from the controller (16) and generate acontrol unit output signal (MOPCS, PDCVS) that drives at least one of a)the hydraulic proportional directional control valve (V, V1, V2), b) thepneumatic proportional directional control valve (P1, P2, P3), and c)the electric motor (940 e, 941 e, 942 e) for control movement of thevalve pin.
 23. The system of claim 22 wherein the at least one inputinterface (1506) receives the valve control signal (VS) either directlyfrom the injection molding machine (IMM) controller (MC) or indirectlyfrom an intermediate control unit (HPU) that receives a correspondinginstruction signal (SPS) from the injection molding machine (IMM) thatis at least indicative of valve open and valve closed or start ofinjection cycle and end of injection cycle.